Kaisai K2OC-18HFN32 Service Manual Download Page 2

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CONTENTS

1. General information of Outdoor Units .................................. 2

2. Features .................................................................................. 3

3. Dimensions ............................................................................. 4

4. Refrigeration Cycle Diagram ................................................. 5

5. Wiring diagram ....................................................................... 7

6. Indoor units combination .................................................... 11

7. Sound Levels ........................................................................ 13

8. Installation Details ............................................................... 14

8.1 Wrench torque sheet for installation ........................................................................... 14

8.2 Connecting the cables ................................................................................................ 14

8.3 Pipe length and the elevation ..................................................................................... 14

8.4 Installation for the first time ......................................................................................... 15

8.5 Adding the refrigerant after running the system for many years ................................ 18

8.6 Re-installation while the indoor unit need to be repaired ........................................... 19

8.7 Re-installation while the outdoor unit need to be repaired ......................................... 21

9. Electronic control function ................................................. 23

10. Troubleshooting ................................................................. 28

Caution:

Risk of fire R32/flammable materials

Summary of Contents for K2OC-18HFN32

Page 1: ...SERVICE MANUAL R32 SUPER DC INVERTER MULTI TYPE K2OC 18HFN32 K3OE 27HFN32 K4OB 36HFN32 K5OD 42HFN32 DC MULTI OUTDOOR UNITS...

Page 2: ...t for installation 14 8 2 Connecting the cables 14 8 3 Pipe length and the elevation 14 8 4 Installation for the first time 15 8 5 Adding the refrigerant after running the system for many years 18 8 6...

Page 3: ...formation of Outdoor Units Model name Dimension mm Compressor K2OC 18HFN32 800x333x554 KSM135D23UFZ K3OE 27HFN32 845x363x702 KTF235D22UMT K4OB 36HFN32 946x410x810 KTF310D43UMT K5OD 42HFN32 946x410x810...

Page 4: ...t cabinet Valve protection cover Discharge pipe temperature protection 2 Features the heating efficiency at operation mode It protects the valves and prevents water from dripping Power relay control L...

Page 5: ...4 3 Dimensions A D B Model Unit mm W D H W1 A B K2OC 18HFN32 800 333 554 860 514 340 K3OE 27HFN32 845 363 702 923 540 350 K4OB 36HFN32 946 410 810 1034 673 403 K5OD 42HFN32 946 410 810 1034 673 403...

Page 6: ...o r C o m p re s s o r T 5 D is c h a rg e te m p s e n s o r C O O L I N G H E A T I N G 4 2 Refrigeration circuit drawing of inverter 1 drive 3 type E X V A C A P I L L A R Y A L I Q U I D V A L V E...

Page 7: ...h a rg e te m p s e n s o r C O O L IN G H E A T IN G 4 4 Refrigeration circuit drawing of inverter 1 drive 5 type IN D O O R O U T D O O R E X V A C A P I L L A R Y A L I Q U I D V A L V E A E X V B...

Page 8: ...7 5 Wiring diagram K2OC 18HFN32...

Page 9: ...8 Note S 1 S 2 areusedinothertypeofmodels Theydon tneedtobeconnectedinmultimodels K3OE 27HFN32...

Page 10: ...9 K4OB 36HFN32...

Page 11: ...10 K5OD 42HFN32...

Page 12: ...7 9 24 9 9 18 12 12 18 7 7 7 9 7 7 12 12 7 9 12 1 8 9 9 12 18 1 2 7 12 12 1 2 7 7 1 2 7 12 1 2 9 9 24 12 12 24 7 7 7 12 7 7 12 18 7 9 18 1 8 9 12 12 1 2 1 8 7 18 12 1 8 7 7 1 8 7 12 1 8 9 12 1 2 12 1...

Page 13: ...18 18 7 9 9 7 18 18 9 12 24 9 12 7 9 12 9 9 9 9 18 18 Four Unit 7 7 7 7 7 7 9 18 7 9 9 12 7 12 12 12 9 9 12 12 7 7 7 9 7 7 9 24 7 9 9 18 7 12 12 18 9 9 12 18 7 7 7 12 7 7 12 12 7 9 9 24 7 12 12 24 9 9...

Page 14: ...Unit 7 7 7 7 7 7 7 7 9 18 7 7 9 9 24 7 9 9 12 12 9 9 9 12 12 7 7 7 7 9 7 7 7 9 24 7 7 9 12 18 7 9 9 12 18 9 9 9 12 18 7 7 7 7 12 7 7 7 12 18 7 7 12 12 12 7 9 12 12 12 9 9 12 12 12 7 7 7 7 18 7 7 7 18...

Page 15: ...14 Microphone H 7 Sound Levels Outdoor Unit 1 0m Note H 0 5 height of outdoor unit Model Noise Power dB A Noise level dB A K2OC 18HFN32 56 53 K3OE 27HFN32 65 59 K4OB 36HFN32 68 63 K5OD 42HFN32 71 62...

Page 16: ...the side panel of the unit Please refer to the nameplate before selecting the cable fuse and switch 8 3 Pipe length and the elevation Maximum piping length and height difference 1 drive 2 1 drive 3 1...

Page 17: ...iquid 6 35 1 4 5 Gas 9 52 3 8 4 12 7 1 2 1 8 4 Installation for the first time Air and moisture in the refrigerant system have undesirable effects as below Pressure in the system rises Operating curre...

Page 18: ...please check if there are some leakage points Fully close the handle Lo valve of the manifold valve and stop the operation of the vacuum pump Confirm that the gauge needle does not move approximately...

Page 19: ...harge set to purge the air be careful of the liquid refrigerant 3 Put the charging cylinder onto the electronic scale and record the weight 4 Operate the air conditioner at the cooling mode 5 Open the...

Page 20: ...careful of the liquid refrigerant 3 Put the charging cylinder onto the electronic scale and record the weight 4 Operate the air conditioner at the cooling mode 5 Open the valves Low side on the charge...

Page 21: ...rvice port 3 Air purging of the charge hose Open the handle Lo valve of the manifold valve slightly to purge air from the charge hose for 5 seconds and then close it quickly 4 Set the 2 way valve to t...

Page 22: ...pumping 50 minutes please check if there are some leakage points Fully close the handle Lo valve of the manifold valve and stop the operation of the vacuum pump Confirm that the gauge needle does not...

Page 23: ...position 2 Connect the vacuum pump to 3 way valve s service port 3 Evacuation for approximately one hour Confirm that the compound meter indicates 0 1Mpa 4 Close the valve Low side on the charge set t...

Page 24: ...charge set and charge the system with liquid refrigerant If the system cannot be charge with the specified amount of refrigerant or can be charged with a little at a time approximately 150g each time...

Page 25: ...y function In standby the LED displays In compressor operation the LED display the running frequency In defrosting mode The LED displays dF or alternative displays between running frequency and dF eac...

Page 26: ...A evaporator outlet temperature T2BA If the temperature is lower than 9 the digital display shows 9 If the temperature is higher than 70 the digital display shows 70 If the indoor unit is not connecte...

Page 27: ...y T2 Bit3 Frequency limit caused by T3 Bit2 Frequency limit caused by T5 Bit1 Frequency limit caused by current Bit0 Frequency limit caused by voltage 43 Average value of T2 Sum T2 value of all indoor...

Page 28: ...urrent limit is same as range of T4 limited frequency Cooling mode T4 C o o lZ o n e 1 Heating mode T4 9 5 5 Indoor outdoor units communication protection If the indoor units cannot receive the feedba...

Page 29: ...equency for setting time and then resume to former frequency 2 The EXV will keep 300p while the indoor units will keep the current running mode If the outdoor ambient is higher than setting frequency...

Page 30: ...Water level alarm EE X 8 Overcurrent protection For some units F0 O 1 Open or short circuit of T4 temperature sensor F1 O 2 Open or short circuit of T3 temperature sensor F2 O 3 Open or short circuit...

Page 31: ...or PCB and display board Eb Overload current protection F0 Outdoor ambient temperature sensor T4 open circuit or short circuit F1 Condenser coil temperature sensor T3 open circuit or short circuit F2...

Page 32: ...r of sensor is defective F3 No C Indoor unit coil outlet temperature sensor or connector of sensor is defective F4 No D Indoor unit coil outlet temperature sensor or connector of sensor is defective F...

Page 33: ...it 10 3 1 1 Indoor EEPROM malfunction Yes EEPROM An electrically erasable programmable read only memory whose contents can be erased and reprogrammed using a pulsed voltage Power off then restart the...

Page 34: ...the all indoor units Is IPM powerLED oroperating LED lamp No On Refer PIC2 Yes Power on by remote controller IIs it still displaying the error code after 3 minutes Is main board lampon ReferPIC3 Is t...

Page 35: ...34 Pic 1 check the voltage of N to S Vs is it moving alternately between positive value and negative value Pic 2 IPM or outdoor main PCB Pic 2 IPM or outdoor main PCB Power Self Check Operating...

Page 36: ...35 PIC3 Main board LED when power on and unit standby PIC 4 check point button Press 1 time for check how many indoor units are connected...

Page 37: ...e replaced 2 Indoor DC fan motor control chip is inside fan motor Power on and when the unit is in standby measure the voltage of pin1 pin3 pin4 pin3 in fan motor connector If the value of the voltage...

Page 38: ...r Signal Voltage 1 Red Vs Vm 280V 380V 2 3 Black GND 0V 4 White Vcc 14 17 5V 5 Yellow Vsp 0 5 6V 6 Blue FG 14 17 5V For other types NO Color Signal Voltage 1 Red Vs Vm 192V 380V 2 3 Black GND 0V 4 Whi...

Page 39: ...No Yes Yes Yes Repllace the iindoor maiin PCB Repllace the water pump If mallfunctiion iisstiill ll not sollved Checktheconnectiions between temperature sensor and PCB Are the connectiionsgood Yes Is...

Page 40: ...ecting line between main board and the PFC No module IPM module is connected tightly 10 3 1 7 Communication error between the indoor PCB and display board Yes Yes Yes Replace the Display board Replace...

Page 41: ...dule protection 10 3 3 For the outdoor unit 10 3 3 1 Outdoor EEPROM malfunction ODU E0 Yes EEPROM An electrically erasable programmable read only memory whose contents can be erased and reprogrammed u...

Page 42: ...board and the main board is it connected good Yes No Yes Reconnect and retry Is error still display No No Replace IPM board and then check whether the system can run normally Yes No Replace outdoor m...

Page 43: ...Replace bridge rectifiers and then check whether the system can run normally Yes Yes No Replace IPM board and then check whether the system can run normally Yes No Trouble is solved Replace outdoor ma...

Page 44: ...showing in below table the PCB must have problems and need to be replaced DC motor voltage input and output NO Color Signal Voltage 1 Red Vs Vm 140V 380V 2 3 Black GND 0V 4 White Vcc 13 5 16 5V 5 Yell...

Page 45: ...eck iifthe outdoor uniit ventiillatiion iis good NO Yes Check iifthe outdoor fan runs properlly No Yes Check whether the heat exchanger iis diirty Yes No Repllace outdoor maiin board No Check whether...

Page 46: ...normall the vallue iis o o o No Yes Check whether theoutdoor ambiient temperature iistoo llow Yes Low pressure protection Check whether valve core ofhighpressurevalveis opened No Yes Check iifthe iind...

Page 47: ...refrigerant to blow pipe vacuumize and charge the refrigerant again Judge 1 Check whether the input current of the power supply wire is higher than max protection current value Yes Check whether the r...

Page 48: ...temp sensor and PCB accordiing to wiiriing diiagrams No Temperatureprotectionof compressor discharge Correct the wiiriing connectiion Stop lleakiing and add refriigerant 10 3 3 8 Temperature protecti...

Page 49: ...ix 1 No Yes Check whetther tthe outtdoor ambiientt ttemperatture iis hiigher tthan 50 Yes No Checkiiftheoutdoor uniit ventiillatiion iis good No Yes Check iifthe outdoor fan runs properlly No Yes Chec...

Page 50: ...No Check whether the bridge rectifiers are normal Use the multimeter to measure the resistance between each two terminals check whether there is the condition that value of resistance is 0 No Check i...

Page 51: ...nit get warm Potential causes Faulty EXV Wire and piping connected in reverse Check of EXV please refer to part 5 in 10 4 Trouble Criterion Of Main Parts Automatic correction of wiring piping error Pr...

Page 52: ...e the resistance value with a tester Temperature Sensors Room temperature T1 sensor Indoor coil temperature T2 sensor Outdoor coil temperature T3 sensor Outdoor ambient temperature T4 sensor Compresso...

Page 53: ...1 34105 116 0 40060 3 41 5878 37 5 87359 77 1 29078 117 0 38991 2 39 8239 38 5 62961 78 1 25423 118 0 37956 1 37 1988 39 5 39689 79 1 21330 119 0 36954 0 35 2024 40 5 17519 80 1 17393 120 0 35982 1 33...

Page 54: ...9 5 234 9 35 35 78 75 8 084 115 2 422 4 222 8 36 34 32 76 7 82 116 2 357 3 211 4 37 32 94 77 7 566 117 2 294 2 200 7 38 31 62 78 7 321 118 2 233 1 190 5 39 30 36 79 7 086 119 2 174 0 180 9 40 29 15 80...

Page 55: ...54 2 Compressor checking Measure the resistance value of each winding by using the tester Position Resistance Value KSM135D23UFZ KTF235D22UMT KTF310D43UMT Blue Red 1 72 20 0 75 20 0 65 20...

Page 56: ...tester Normal resistance value Red Black Several M Red Black Several M P N U N U V V W W Red 4 4 way valve 1 Power on use a digital tester to measure the voltage when the unit operates in cooling it...

Page 57: ...56 5 EXV check Disconnect the connectors Resistance to EXV coil Color of lead wire Normal Value Red Blue About 50 Red Yellow Brown Orange 6 5 4 3 2 1 Red Brown Blue Orange Yellow White...

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